“Moving Forward Efficiently”
HEV/EV Traction Motor Lab
Mark Ramseyer, Staff Technical Application Engineer
Terry Downs, Staff Technical Application Engineer
A traction motor is an electric motor providing the primary rotational
torque of a machine, usually for conversion into linear motion (traction).
Class ID: 0L04A
Renesas Electronics America Inc.
© 2012 Renesas Electronics America Inc. All rights reserved.
Mark Ramseyer
 Staff Technical Application Engineer
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Digital Circuit Design
Resolver/RDC Interfaces
Model Based Development (MBD)
Virtualization, Co-simulation, HIL simulation
 22 Years Embedded Microcontroller Development
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Microcontroller specification
IC design, verification, simulation and timing
PCB circuit design and layout
Controller system design
Software and firmware development
Compilers and software tools
Calibration and data acquisition tools
 Ford Motor Co., Ford Microelectronics, Visteon, General
Motors
 BS in Computer & Electrical Engineering from
2
© 2012 Renesas Electronics America Inc. All rights reserved.
Terry Downs
 Technical Application Engineer
 Embedded Software
 Digital Circuit Design
 Motor Control Driver and Algorithm Design
 25 Years Embedded Microcontroller Development
 IC specification and verification
– Microcontrollers
– Flash Memory
 IC packaging
 IC quality
 Electronic controller manufacturing
 Electronic module design
 Software development
 Ford Electronics, Visteon, General Motors Powertrain
 BSEE – Lawrence Technological University
 MSEE – University of Michigan
3
© 2012 Renesas Electronics America Inc. All rights reserved.
Renesas Technology & Solution Portfolio
4
© 2012 Renesas Electronics America Inc. All rights reserved.
Microcontroller and Microprocessor Line-up
2010
2013
1200 DMIPS, Superscalar
32-bit
 Automotive & Industrial, 65nm
 600µA/MHz, 1.5µA standby
1200 DMIPS, Performance
 Automotive, 40nm
 500µA/MHz, 35µA deep standby
500 DMIPS, Low Power
 Automotive & Industrial, 90nm
 600µA/MHz, 1.5µA standby
165 DMIPS, FPU, DSC
 Industrial, 40nm
 242µA/MHz, 0.2µA standby
165 DMIPS, FPU, DSC
 Industrial, 90nm
 242µA/MHz, 0.2µA standby
8/16-bit
25 DMIPS, Low Power
 Industrial, 90nm
 1mA/MHz, 100µA standby
 Industrial & Automotive, 150nm
 190µA/MHz, 0.3µA standby
44 DMIPS, True Low Power
10 DMIPS, Capacitive Touch
 Industrial & Automotive, 130nm
 144µA/MHz, 0.2µA standby
 Industrial & Automotive, 130nm
Wide
Format LCDs
 350µA/MHz, 1µA standby
5
Embedded Security, ASSP
© 2012 Renesas Electronics America Inc. All rights reserved.
Microcontroller and Microprocessor Line-up
2010
2013
1200 DMIPS, Superscalar
32-bit
 Automotive & Industrial, 65nm
 600µA/MHz, 1.5µA standby
1200 DMIPS, Performance
 Automotive, 40nm
 500µA/MHz, 35µA deep standby
500 DMIPS, Low Power
32-Bit High Performance, 165 DMIPS, FPU, DSC
High Efficiency & Integration  Industrial, 40nm
 Automotive & Industrial, 90nm
 600µA/MHz, 1.5µA standby
 242µA/MHz, 0.2µA standby
165 DMIPS, FPU, DSC
 Industrial, 90nm
 242µA/MHz, 0.2µA standby
8/16-bit
25 DMIPS, Low Power
 Industrial, 90nm
 1mA/MHz, 100µA standby
 Industrial & Automotive, 150nm
 190µA/MHz, 0.3µA standby
44 DMIPS, True Low Power
10 DMIPS, Capacitive Touch
 Industrial & Automotive, 130nm
 144µA/MHz, 0.2µA standby
 Industrial & Automotive, 130nm
Wide
Format LCDs
 350µA/MHz, 1µA standby
6
Embedded Security, ASSP
© 2012 Renesas Electronics America Inc. All rights reserved.
Production Vehicles with Traction Motors
Kia
Optima
MY = Model Year of Introduction
Source: www.hybridcenter.org
Hybrids Millions
0.5
Porsche
Cayenne
Infiniti
M
Total U.S. Vehicle Sales
0.4
15
VW
Touareg
12
BMW
750i
0.3
Mitsubishi Lincoln
I MiEV
0.2
Cadillac
Escalade
Honda Toyota
Accord Highlndr
0.1
MKZ
Civic
9
Honda Renault
CR-Z Fluence
BMW Hyundai Smart
X6
Sonata
ED
Ford
Nissan
Silverado Fusion
Leaf
BYD
e6
Nissan Chevy Dodge Mercedes Chevy
Escape RX400 Altima Tahoe Durango ML450
Volt
Tesla
S
Chevy
ToyotaHonda
Prius Drivetrain
Toyota
Ford Lexus
Prius
Total Millions
18
6
3
Ford
Focus
0
1997 … 2003 2004
7
0
2005
2006
© 2012 Renesas Electronics America Inc. All rights reserved.
2007
2008
2009
2010
2011
2012
2013
Traction Motor Efficiency
 HEV/EV overall efficiency
is a key metric.
(35kWh / 100mi)
 HEV/EV “all electric”
range is a key metric.
(38 miles using pure electric)
 Traction motors are ~70-90% efficient
 Depending on RPM, other factors
 Convert electrical energy to mechanical energy
 Traction motor efficiency is a primary factor in HEV/EV
performance
 Electrical energy storage/retrieval are ~70-80% efficient
 Convert electrical energy to chemical energy, and then back
 See DevCon presentation about battery management
8
© 2012 Renesas Electronics America Inc. All rights reserved.
Renesas ‘Smart Society’ Traction Motor Control
 Industry’s Only Integrated Algorithm Hardware
 Park/Clarke transformations, PI controller, Duty Cycle
Calculation
 Completely coherent angle and current samples
 Industry’s Only Integrated RDC Hardware
 Industry leading Tamagawa resolver-to-digital converter (RDC)
 Optimized, Flexible PWM Generation Peripheral
 2 Motor Control with Single Micro
 Full hardware & RDC support for 2 motors on next gen micro
 Software Driver Generation using QuantiPhi
 Less Expense & Faster Development
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© 2012 Renesas Electronics America Inc. All rights reserved.
Agenda
 Typical Traction Motor Subsystem
 Renesas “Smart Society” Solution
 IRIS Evaluation Platform
 Resolver & RDC Lab
 Software & External RDC Motor Control Lab
 EMU & Integrated RDC Motor Control Lab
 Conclusion
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© 2012 Renesas Electronics America Inc. All rights reserved.
Typical Traction Motor Subsystem
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© 2012 Renesas Electronics America Inc. All rights reserved.
Typical Hardware Architecture
3 sinusoidal current waveforms
6 aligned, continuously changing PWMs
(5V digital outputs)
Micro
3 x IGBT
module
(6 x IGBT)
Motor Position
Motor Position
digital angle
RDC
Motor Position
Motor with resolver
Resolver output:
Sin/Cos depending on motor position
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© 2012 Renesas Electronics America Inc. All rights reserved.
Resolver Operation
 Absolute angle sensor
 Resolves (modulates) angle into orthogonal pieces: sine & cosine
signals
 Essentially a rotating transformer with specifically positioned
secondaries
 Every angle has unique combination of sine & cosine, yielding an
absolute angle
Cosine output:
kV cos θ sin ωt
Excitation input:
V sin ωt
k = transformation ratio
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Sine output:
kV sin θ sin ωt
© 2012 Renesas Electronics America Inc. All rights reserved.
Sources: Tamagawa Seiki & admotec
60
140
50
120
100
40
80
30
60
20
mm
$ and #
Resolver History
40
10
20
0
0
1960
Price ($)
1970
1980
1990
# Components
2000
Width (mm)
Source: Tamagawa Seiki, for 52mm diameter resolver
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© 2012 Renesas Electronics America Inc. All rights reserved.
RDC Operation
 Performs implicit arctangent
 Uses trigonometry identity: sin(θ – φ) = sinθ cosφ – cosθ sinφ
 Uses approximation: sin(θ – φ) ≈ θ – φ, for θ – φ < ±30°
 To generate difference error, ε, between actual motor angle,
θ, and RDC digital angle, φ
ε ≈ kV (θ – φ) sinωt

 As the difference error, ε, approaches 0, θ = φ and digital
angle equals actual motor angle
 Provides resolution better than 0.1°
RDC
Analog
kV sin θ sin ωt
resolver
buffer
cos ROM
* D/A
+
cmp
kV cos θ sin ωt
buffer
* D/A
θ
Vsinωt
15
amp
© 2012 Renesas Electronics America Inc. All rights reserved.
-
Sync
detection
ε
compare
sin ROM
exc. sig.
generator
Digital
counter
φ
Motor Timer Peripheral – Phase Counting
 The MTU-III
 A multi-function timer pulse unit with eight 16-bit channels
 Phase counting mode is used for an RDC’s quadrature encoded
angle signal
Ch 0 Ch 1 Ch 2 Ch 3 Ch 4 Ch 5 Ch 6 Ch 7
RDC RDC
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© 2012 Renesas Electronics America Inc. All rights reserved.
Motor 1
Motor 2
Motor Timer Peripheral - PWM Generation
 Generate a periodic time interval
 Trigger interrupts for A/D Conversion, Angle Sample
 Given 3 duty cycles generate 6 PWM signals
 Coordination of several up/down counters and thresholds
 Enforce dead time to prevent shoot-through current
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© 2012 Renesas Electronics America Inc. All rights reserved.
Motor Timer Peripheral – PWM Generation
 The MTU-III
 A multi-function timer pulse unit with eight 16-bit channels
 Complementary PWM mode is used for motor control
Ch 0 Ch 1 Ch 2 Ch 3 Ch 4 Ch 5 Ch 6 Ch 7
Motor 1
Motor 2
PWM Carrier Cycle Reg’s
Comparator
Match
Signals
MTU
Ch 6, 7 Timers
Comparator
Match
Signals
Coil Duty Cycle Reg’s
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© 2012 Renesas Electronics America Inc. All rights reserved.
Output Controller
PWM Carrier Output
PWM1 H/L
PWM2 H/L
PWM3 H/L
Software Responsibilities - Traditional
Trough
ADC
Trigger
ADC
Complete
ISR
Call Motor
Algorithm
Re-Arm ADC
Carrier
Trough
ISR
Motor
Algo.
Angle count
from MTU
Current to
Amps
Voltage
Bounds Check
Calculate
Elec. Angle
Clarke & Park
Transforms
Duty Cycle
Calculation
Return
from
ISR
Q Vector PI
Control Loop
Timer Match
Calculation
D Vector PI
Control Loop
Write match
values to Timer
Inverse
Transforms
Return
Return
from
ISR
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© 2012 Renesas Electronics America Inc. All rights reserved.
Renesas “Smart Society” Solution
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© 2012 Renesas Electronics America Inc. All rights reserved.
Renesas Smart Architecture
6 aligned, continuously changing PWMs
(5V digital outputs)
1 Micro with
2 RDCs
Motor 1
See DevCon presentation about IGBTs
3 x IGBT
module
(6 x IGBT)
3 sinusoidal current waveforms
Motor 1
Motor 1
Motor 2
Motor 2
Motor 2
Motor Position
Motor Position
Motor 1
Motor 2
No external RDCs
Motor Position
Resolver output:
Sin/Cos depending on motor position
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© 2012 Renesas Electronics America Inc. All rights reserved.
Motor 1
2 motors
with
resolvers
Motor 2
Integrated RDC
 Performs same arctangent operation
 To generate difference same difference ε
 To make the digital angle equal actual motor angle
 Still provides resolution better than 0.1°
Micro
Analog
kV sin θ sin ωt
resolver
buffer
cos ROM
* D/A
+
cmp
kV cos θ sin ωt
buffer
* D/A
θ
Vsinωt
22
amp
© 2012 Renesas Electronics America Inc. All rights reserved.
-
Sync
detection
ε
compare
sin ROM
exc. sig.
generator
Digital
counter
φ
EMU Peripheral (Enhanced Motor Control Unit)
Application
Id & Iq Request
Motor Control Section
Feedback
Vector
Transforms
PI Control
Loop
3-Phase Waveform
Output Section
Inverse
Vector
Transforms
Timer Unit
PWM
Outputs
Duty Cycle
Calculation
Conversion
to Timer
Counts
Carrier
Timing
EMU
SH72AY
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© 2012 Renesas Electronics America Inc. All rights reserved.
Trigger to ADC
PWMs to Motor
Current and Angle
Manipulation
Data from RDC
Data from ADC
Data Transfer
Section
Software Responsibilities – Renesas Solution
ADC
Trigger
ADC
Complete
ISR
Carrier
Trough
ISR
Angle count
from MTU
Calculate
Elec. Angle
Call Motor
Algorithm
Re-Arm ADC
Return
from
ISR
Return
from
ISR
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© 2012 Renesas Electronics America Inc. All rights reserved.
Motor
Algo.
EMU
Complete
ISR
Current to
Amps
Voltage
Bounds Check
Re-Arm ADC
Clarke & Park
Transforms
Duty Cycle
Calculation
Q Vector PI
Control Loop
Timer Match
Calculation
D Vector PI
Control Loop
Write match
values to Timer
Inverse
Transforms
Return
Return
from
ISR
IRIS Evaluation Platform
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© 2012 Renesas Electronics America Inc. All rights reserved.
IRIS Goals
 Provide investigation system of Renesas solution to OEMs
and Tier 1s
 Encourage use within OEM and Tier 1 development systems
 Show efficiencies of Renesas integrated RDC
 Show performance advantages of Renesas Enhanced Motor
control timer Unit (EMU)
 Highlight cost savings & better performance
 Evaluate RDC vs. resolver inter-operation
 Evaluate RDC performance with injected noise
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© 2012 Renesas Electronics America Inc. All rights reserved.
IRIS Capabilities
 Support for 2 motors
 Software selectable RDC per motor
 4 different external RDCs
 1 internal RDC
 1 FPGA simulated RDC
 Software selectable resolver per motor
 Motor resolver
 FPGA simulated resolver
 Resolver Flexibility
 Excitation voltage of 5V to 15V
 Practically any transformation ratio
 2 FPGA simulated motors and resolvers, including current
and voltage feedbacks
 Isolated, low skew (< 10ns) motor PWMs and control/status
 2 x CAN, 1 x RS-232, 1 x isolated USB
 Robust inputs
 Automotive capable 6V – 30V supply
 Most inputs protected for short to power/ground
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© 2012 Renesas Electronics America Inc. All rights reserved.
Simplified IRIS Diagram
USB
USB
ATI A7
Data Acq. &
Calibration Tool
• Control software
• Drivers
Micro D’board
• Micro Daughterboard
• Current, voltage, temp inputs
• Multiple RDCs & resolver circuits
• FPGA motor simulator
• CAN x 2
• Power supplies
• LEDs, switches
•
•
•
•
IGBTs/MOSFETs
Gate drivers
Volt, current sensors
Temp sensors
Control Board (ECU)
CAN x 2
sin, cos, exc
•
•
•
•
IGBTs/MOSFETs
Gate drivers
Volt, current sensors
Temp sensors
Inverter Board
Power Supply
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© 2012 Renesas Electronics America Inc. All rights reserved.
Motor &
resolver
1
Inverter Board
harness
micro debug port
Motor &
resolver
2
IRIS Control Board Block Diagram
USB
SH72AY micro
Debug port
ATI A7
Data Acq. &
Calibration Tool
Micro Daughterboard
Motor
Control
PWM
FPGA
Motor
Simulator
Micro socket
CAN
x2
Motor
Control
CAN
Txcvr
PWM
Motor
Feedback
Motor
Feedback
Power
Supply
Analog
Muxes
Analog
Muxes
AU6802
RDC
AU6802
RDC
AU6803
RDC
AU6803
RDC
AD2S1205
RDC
AD2S1205
RDC
AD2S1210
RDC
AD2S1210
RDC
Control Board (ECU)
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© 2012 Renesas Electronics America Inc. All rights reserved.
current, voltage,
temp
current, voltage,
temp
Analog
Muxes
Analog
Muxes
sin, cos
exc
sin, cos
exc
IRIS Software Architecture
Motor 1 – Control via EMU
Configuration SW
Speed Control App
Configuration SW
Speed Control App
Ext
RDC
ADC
RDC
ADC
Motor 2 – Control via Software
ISR1
EMU
ISR2
• Input Processing
• Coordinate Transforms
• PI Controller
• Duty Cycle Calculation
MTU-III
IGBTs
Registers
Motor Resolver
IGBTs
Motor Resolver
User interface through AUD connection
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© 2012 Renesas Electronics America Inc. All rights reserved.
Resolver & RDC Lab
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© 2012 Renesas Electronics America Inc. All rights reserved.
Resolver & RDC Lab
motor coils
connector
50W motor
resolver
resolver
connector
sine wave
excitation signal
sine/cosine
resolver signals
 Do not connect motor coils
 Turn motor shaft by hand
 Watch resolver response
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© 2012 Renesas Electronics America Inc. All rights reserved.
oscilloscope
Software & External RDC Motor Control Lab
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© 2012 Renesas Electronics America Inc. All rights reserved.
Software & External RDC Motor Control Lab
50W
motor
resolver
sine/cosine
resolver signals
resolver
connector
AUD
excitation
signal
Motor
PWMs
Motor
connector
Motor
Coils
Inverter
Board
ATI VISION & A7E
34
© 2012 Renesas Electronics America Inc. All rights reserved.
EMU & Integrated RDC Motor Control Lab
35
© 2012 Renesas Electronics America Inc. All rights reserved.
EMU & Integrated RDC Motor Control Lab
50W
motor
resolver
sine/cosine
resolver signals
AUD
resolver
connector
excitation signal
motor
connector
Motor PWMs
Motor
Coils
Inverter
Board
ATI VISION & A7E
36
© 2012 Renesas Electronics America Inc. All rights reserved.
Conclusion
37
© 2012 Renesas Electronics America Inc. All rights reserved.
‘Smart Society’ Traction Motor Control
 Resolver-to-Digital Converters (RDCs) provide accuracy for
high traction motor efficiency
 Integrated algorithm hardware allows for control of 2
traction motors with 1 micro
 Significant cost savings can be gained by RDC integration
and elimination of 2nd micro for 2nd motor
 Driver generation is real, efficient, practical and even fun
 Renesas Electronics has a really smart, integrated solution
for traction motor control
 It can be evaluated today
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© 2012 Renesas Electronics America Inc. All rights reserved.
Questions?
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© 2012 Renesas Electronics America Inc. All rights reserved.
Please Provide Your Feedback
 Please utilize the ‘Guidebook’ application to leave feedback
 Or, ask for the paper feedback form
40
© 2012 Renesas Electronics America Inc. All rights reserved.
Renesas Electronics America Inc.
© 2012 Renesas Electronics America Inc. All rights reserved.